Real-Time Monitoring of Induction Motor Parameters Using ESP32 and MQTT Protocol

Three-phase induction motors are widely used in industrial systems and are responsible for a significant portion of electricity consumption. Monitoring their operating conditions is essential to support maintenance strategies and reduce unexpected downtime. This work presents the development and implementation of a real-time monitoring system for electrical and mechanical parameters of three-phase induction motors using embedded Internet of Things (IoT) technologies. The proposed system integrates an ESP32 microcontroller with multiple sensors for measuring temperature, vibration, current, and voltage. The collected data are transmitted wirelessly using the MQTT protocol to a monitoring interface built in Python, providing real-time visualization through a graphical dashboard. The firmware was developed using FreeRTOS to manage concurrent tasks for sensor acquisition and data transmission, ensuring synchronization and efficient processing. Prototyping involved two custom-printed circuit boards (PCBs): one for sensor data acquisition and system management and another dedicated to power quality measurement using the ADE7758 chip. Validation tests were conducted by coupling the system to a three-phase induction motor under laboratory conditions. The temperature and vibration sensors recorded readings that varied according to motor behavior, with the vibration sensor capturing signals during both motor startup and steady-state operation. Electrical measurements included current and voltage values obtained through the power quality monitoring circuit, with variations observed in specific intervals due to noise and assembly-related factors.